Smokeless Tobacco

ABSTRACT

A smokeless tobacco formulation includes particles or pieces of tobacco, and may include other ingredients, such as salts, sweeteners, binders, colorants, pH adjusters, fillers, flavoring agents, disintegration aids, antioxidants, humectants, and preservatives. The moisture content of the particles of the tobacco may vary. Certain smokeless tobacco products have the form of tobacco compositions or formulations that result from casting or otherwise forming a slurry incorporating tobacco material and other components as a film or sheet. Certain smokeless tobacco products have the form of tobacco compositions or formulations that result from pressing, extruding or otherwise forming a mixture incorporating tobacco material and other components into a desired shape. The foregoing tobacco products, as well as snus-type products, can be packaged under conditions of controlled atmosphere. Smokeless tobacco products can be sealed in outer packaging materials that are virtually impervious to oxygen and/or moisture, and those packaging materials can be vacuum sealed or sealed such that the atmosphere therewithin is essentially inert.

FIELD OF THE INVENTION

The present invention relates to tobacco, and in particular, to tobaccoformulations suitable for use in a smokeless manner, and to the handlingand use of tobacco that is in a smokeless form.

BACKGROUND OF THE INVENTION

Cigarettes, cigars, little cigars and pipes are popular smoking articlesthat employ tobacco in various forms. Smoking articles are tobaccoproducts that are used by heating or burning tobacco, and aerosol (e.g.,smoke) is inhaled by the smoker. Representative manners or methods thathave been proposed for the packaging of tobacco products, includingcigarettes and cigars, are set forth in U.S. Pat. No. Des 368,221 toMontague; U.S. Pat. No. 1,886,115 to Muller; U.S. Pat. No. 3,371,775 toButler; U.S. Pat. No. 3,967,730 to Driscoll et al.; U.S. Pat. No.4,852,734 to Allen et al.; U.S. Pat. No. 5,139,140 to Burrows et al.;U.S. Pat. No. 5,333,729 to Wolfe; U.S. Pat. No. 5,542,529 to Hein, IIIet al.; U.S. Pat. No. 5,938,018 to Keaveney et al. and U.S. Pat. No.7,014,039 to Henson et al.; each of which is incorporated herein byreference.

Tobacco also may be enjoyed in a so-called “smokeless” form.Particularly popular smokeless tobacco products are employed byinserting some form of processed tobacco or tobacco-containingformulation into the mouth of the user.

Various types of smokeless tobacco products are set forth in U.S. Pat.No. 1,376,586 to Schwartz; U.S. Pat. No. 4,513,756 to Pittman et al.;U.S. Pat. No. 4,528,993 to Sensabaugh, Jr. et al.; U.S. Pat. No.4,624,269 to Story et al.; U.S. Pat. No. 4,987,907 to Townsend; U.S.Pat. No. 5,092,352 to Sprinkle, III et al.; U.S. Pat. No. 5,387,416 toWhite et al.; and Des. 335,934 to Howard; U.S. Pat. App. Pub. No.2005/0244521 to Strickland et al. and 2006/0162732 to Winn et al.; PCTApplication Pub. No. WO 04/095959 to Arnarp et al.; PCT Application Pub.No. WO 05/063060 to Atchley et al.; PCT Application Pub. No. WO05/004480 to Engstrom; and PCT Application Pub. No. WO 05/041699 toQuinter et al.; each of which is incorporated herein by reference. Onetype of smokeless tobacco product is referred to as “snuff.” Snufftypically is formulated in “moist” or “dry” forms. Representative typesof snuff products, commonly referred to as “snus,” are manufactured inEurope, particularly in Sweden, by or through companies such as SwedishMatch AB, Fiedler & Lundgren AB, Gustavus AB, SkandinaviskTobakskompagni A/S and Rocker Production AB. Snus products available inthe U.S.A. are marketed under the tradenames Camel Snus Frost, CamelSnus Original and Camel Snus Spice by R. J. Reynolds Tobacco Company.Representative smokeless tobacco products also are marketed under thetradenames Oliver Twist by House of Oliver Twist A/S; Copenhagen, Skoal,SkoalDry, Rooster, Red Seal, Husky, and Revel by U.S. Smokeless TobaccoCo.; “taboka” by Philip Morris USA; and Levi Garrett, Peachy, Taylor'sPride, Kodiak, Hawken Wintergreen, Grizzly, Dental, Kentucky King, andMammoth Cave by Conwood Sales Co., L.P.

Exemplary manners for providing various types of tobacco products fordistribution to consumers have been proposed in U.S. Pat. No. 3,696,917to Levi; PCT WO 2004/095959 to Arnarp et al. and PCT WO 2005/016036 toBjorkholm; each of which is incorporated herein by reference. Equipmentfor packaging tobacco has been commercially available, andrepresentative equipment has been available as FPP 210 Pouch Packer fromSchur Flexible Benelux.

Smokeless tobacco products are packaged for distribution, sale and usein a variety of ways. Chewing tobacco has been packaged in pouches, foilbags and metal containers. Snus types of products have been packaged intins, “pucks” or “pots” that are manufactured from metal or plastic. Incertain circumstances, smokeless tobacco products are refrigerated priorto sale, typically for the purpose of prolonging the freshness andmoisture content thereof. For example, smokeless tobacco products,particularly moist tobacco products, can be refrigerated in order toavoid or retard absorption of contaminants that provide an undesirableflavor or odor to the product, avoid or retard the developmentdiscoloration or staining of the product, and to avoid or retard theactivity of biologically active microorganisms. For example, smokelesstobacco products, and typically moist snuff types of products, can berefrigerated to retard the effects of enzymatic and other biologicalactivities, pH changes, oxidation, and other effects that have atendency to shorten product shelf-life or stability.

It would be desirable to provide efficient and effective forms ofpackaging for a smokeless tobacco composition or formulation. It alsowould be desirable to provide smokeless tobacco compositions orformulations, and in particular, processed smokeless tobaccocompositions and formulations.

SUMMARY OF THE INVENTION

The present invention relates to a smokeless tobacco product. Theproduct includes a smokeless tobacco composition or formulation. Forexample, the smokeless tobacco formulation includes particles or piecesof tobacco, and may include other ingredients, such as salts,sweeteners, binders, colorants, pH adjusters, fillers, flavoring agents,disintegration aids, antioxidants, humectants, and preservatives. Themoisture content of the particles of the tobacco may vary. Certainsmokeless tobacco products have the form of tobacco compositions orformulations that result from casting or otherwise forming a slurryincorporating tobacco material and other components as a film or sheet.Certain smokeless tobacco products have the form of tobacco compositionsor formulations that result from pressing, extruding or otherwiseforming a mixture incorporating tobacco material and other componentsinto a desired shape.

The tobacco formulation can be contained within a container, such as apouch or bag, such as is the type commonly used for the manufacture ofsnus types of products (e.g., a sealed, moisture permeable pouch that issometimes referred to as a “portion”). A representative moisturepermeable pouch can be composed of a “fleece” type of material. Thetobacco formulation is in turn contained within a package. The packageis sealed tightly, and is composed of a suitable material, such that theatmospheric conditions within that sealed package are modified and/orcontrolled; that is, the sealed package can provide a good barrier thatinhibits the passage of compositions such as moisture and oxygentherethrough; in addition, the atmosphere within the sealed package canbe further modified by introducing a selected gaseous species (e.g.,nitrogen, argon, or a mixture thereof) into the package prior to sealingor by drawing a vacuum therein (vacuum sealing). As such, theatmospheric conditions to which the tobacco composition is exposed arecontrolled during conditions of preparation, packing, storage andhandling.

In one aspect, an individual portion of smokeless tobacco (e.g., onesnus fleece bag containing a smokeless tobacco formulation) can bewrapped in a package. The atmosphere within each package is modified orcontrolled in a manner characteristic of the present invention. Severalsnus fleece bags so packaged then can be contained within the productcontainer, such as a metal or plastic tin.

In one aspect, several individual portions of smokeless tobacco can bewrapped together within one package. The atmosphere within that packageis modified or controlled in a manner characteristic of the presentinvention. That package, or a combination of several of such packages,then can be contained within the product container, such as a metal orplastic tin.

In one aspect, smokeless tobacco product (e.g., several individualportions of smokeless tobacco) can be contained within a sealedcontainer, such as a metal or plastic tin. That container then can bewrapped within a package, such that the atmosphere within that packageand the sealed container is modified or controlled in a mannercharacteristic of the present invention.

In one aspect, smokeless tobacco product (e.g., several individualportions of smokeless tobacco) can be contained within a sealedcontainer, such as a metal or plastic tin, and the atmosphere withinthat sealed container is modified or controlled in a mannercharacteristic of the present invention.

In one aspect, at least one individual portion of smokeless tobacco canbe wrapped in a package. The atmosphere within each package is modifiedor controlled in a manner characteristic of the present invention. Thatpackage or several of those packages then can be contained within theproduct container, such as a metal or plastic tin. The atmosphere withinthat sealed metal or plastic container is modified or controlled in amanner characteristic of the present invention. Alternatively, thatcontainer then can be wrapped within an outer package, such that theatmosphere within that package and the sealed container is modified orcontrolled in a manner characteristic of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to provide an understanding of embodiments of the invention,reference is made to the appended drawings, in which reference numeralsrefer to components of described exemplary embodiments of the invention.The drawings are exemplary only, and should not be construed as limitingthe invention.

FIG. 1 is an enlarged cross-sectional view of a tobacco product in theform of a snus type of product individually wrapped in an outer package.

FIG. 2 is a cross-sectional view of a tobacco product in the form of asnus type of product, wherein several snus-type products are wrapped inan outer package and that outer package is contained within a generallycylindrical plastic or metal tin.

FIG. 3 is a cross-sectional view of a tobacco product in the form of asnus type of product, wherein several snus-type products are containedwithin a generally cylindrical plastic or metal tin, and that tin iswrapped in an outer package.

FIG. 4 is a cross-sectional view of a tobacco product in the form of asnus type of product, wherein several snus-type products are containedwithin a generally cylindrical plastic or metal tin possessing acontrolled atmosphere.

FIG. 5 is cross-sectional view of a tobacco product in the form of asnus type of product, wherein each of several snus-type products areindividually wrapped in an outer package, and are in turn containedwithin a generally cylindrical plastic or metal tin possessing acontrolled atmosphere.

FIG. 6 is a perspective view (partially cut away) of a plurality ofindividually packaged snus types of products, each individual packagebeing connected to another, and an outer container for containing anddispensing those products.

FIG. 7 is an enlarged cross-sectional view of a tobacco product in theform of a snus type of product individually wrapped in an outer package.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, there is shown a first embodiment of arepresentative type of smokeless tobacco product 110. The tobaccoproduct 110 includes a tobacco composition 115 contained in a sealed,moisture permeable pouch 120, thereby providing a tobacco portion 122. Arepresentative moisture permeable pouch can be composed of a fleece typeof material that is sealed shut in order to effectively retain thetobacco composition within the pouch during normal conditions ofhandling. The tobacco product 110 possesses a sealed outer package 125that surrounds and contains the tobacco portion 122 as a type of tightlysealed pouch. The representative outer package 125 possesses an uppersurface 126 and a lower surface 127; and the two faces 128, 129 of a“fin seal” are shown lying essentially parallel to the lower surface ofouter package 125. The outer package 125 is tightly sealed, and isselected from an appropriate material, such that the atmosphere 130within that outer package can be controlled. In addition, the atmosphere130 within the package can be controlled such that the atmosphere iscomposed most predominantly of high purity nitrogen gas, or othersuitable gaseous species. If desired, the embodiment can be altered inorder that the outer package contains a plurality (e.g., 2, 3 or 4) ofindividual tobacco portions. Each of the two ends 131, 132 of the outerpackage is tightly sealed (e.g., heat sealed), and if desired, thoseends can have a serrated appearance, or cut to have the desired visualeffect. Preferably, the length of the inner region of the outer package125 is at least about 10 percent greater than the overall length of thetobacco portion 122, the width of the inner region of the outer package125 is at least about 10 percent greater than the overall width of thetobacco portion 122, and the height of the inner region of the outerpackage 125 is somewhat greater than the overall height of the tobaccoportion 122. For an exemplary embodiment, a snus-type of product has amaximum length of about 20 mm to about 30 mm, a width of about 10 mm toabout 15 mm, and a height of about 5 mm to about 8 mm; thus the outerpackage 125 would have an overall length of at least about 30 mm, awidth of at least about 30 mm, and a height of at least about 5 mm toabout 8 mm; wherein the two end seals 131, 132 of the outer package 125each extend about 5 mm along the width of the outer package 125, and the“fin seal” has a width of about 10 mm. In use, the outer package 125 isopened by the consumer, the tobacco portion 122 is removed from theouter package, and the tobacco portion is enjoyed by the consumer.

Referring to FIG. 2, there is shown a second embodiment of arepresentative smokeless tobacco product 110. The tobacco product 110includes several tobacco compositions 115, 140, 141 each contained in arespective sealed, moisture permeable pouch 120, 145, 146. The tobaccoproduct 110 possesses a sealed outer package 155 that surrounds andcontains all of those individual tobacco portions 125, 157, 158. Thenumber of tobacco portions within the outer package can vary, and can bea number such as 10, 12, 15, 20, 25 or 30. The outer package 155 istightly sealed, and for the representative embodiment shown, the outerpackage 155 possesses a three-sided type of packaging configuration(i.e., the packaging material used to manufacture the outer package issealed on three sides). The outer package 155 is selected from anappropriate material, such that the atmosphere 160 within that outerpackage can be controlled. For example, the atmosphere 160 within thepackage can be controlled such that the atmosphere is composed of highpurity nitrogen gas, or other suitable gaseous species. The outerpackage 155 is contained within a hard container 165, such as a plasticor metal tin having a lower portion 168 and a corresponding orcoordinating upper portion 170. A representative hard container 165 isthe short, rounded edge, generally cylindrical container traditionallyused for the marketing of snus types of products. See, for example, thetypes of representative snuff-box types of designs set forth in PCT WO2005/016036 to Bjorkholm. Other types of containers that can be suitablymodified are plastic or metal type containers set forth in U.S. Pat. No.7,014,039 to Henson et al. See, also, the types of hard containers usedfor the commercial distribution of Camel Snus by R. J. Reynolds TobaccoCompany; Revel Mint Tobacco Packs type of smokeless tobacco product byU.S. Smokeless Tobacco Corporation; SkoalDry by U.S. Smokeless TobaccoCo. and “taboka” by Philip Morris USA. If desired, the type of containerused for the “taboka” product can be adapted to possess a slidable lid(e.g., one that slides generally parallel to the longitudinal axis ofthe container) in order that the container can be opened and closed. Ifdesired, the container can have an accordion or bellows type of design,such that the container can be extended open for filling with smokelesstobacco product during production, and then contracted after filling ofthe container is complete. If desired, containers can be equipped withsuitable seals or grommets, in order that when an opened container isre-shut, a good seal is provided.

In use, the hard container is opened, the outer package is opened, atobacco portion is removed therefrom, and the tobacco portion is enjoyedby the consumer. The hard container can be manually resealed, andadditional tobacco portions can be removed from that container by theconsumer as desired.

Referring to FIG. 3, there is shown a third embodiment of arepresentative smokeless tobacco product 110. The tobacco product 110includes several tobacco compositions 115, 140, 141 each contained in arespective sealed, moisture permeable pouch 120, 145, 146. Thoseindividual pouch sealed tobacco portions 156, 157, 158 are themselvescontained within a hard container 165, such as a plastic or metal tinhaving a lower portion 168 and a corresponding or coordinating upperportion 170. The number of tobacco portions within the hard containercan vary, and can be a number such as 10, 12, 15, 20, 25 or 30. Arepresentative hard container 165 is the short, rounded edge, generallycylindrical container traditionally used for the marketing of snus typesof products. The hard container 165 is in turn packaged within a sealedouter package 180. The representative outer package 180 shown as arepresentative embodiment has a “lap seal” type of sealing mechanism,and as such, possesses an upper surface 182, a lower surface 183, and anoverlap seal 184 located on the bottom face of the outer package. Theouter package 180 is tightly sealed at each end 185, 186, and isconstructed from an appropriate material, such that the atmosphere 160within that outer package, and within the hard container 165, iscontrolled. For example, the atmosphere 160 within the package can becontrolled such that the atmosphere is composed of high purity nitrogengas, or other suitable gaseous species. In use, the outer package 180 isopened, the hard container 165 is opened, and individual tobaccoportions are removed as desired from the hard container.

Referring to FIG. 4, there is shown a fourth embodiment of arepresentative smokeless tobacco product 110. The tobacco product 110includes several tobacco compositions 115, 140, 141 each contained in asealed, moisture permeable pouch 120, 145, 146, respectively. Thoseindividual tobacco portions 156, 157, 158 are contained within a hardcontainer 165, such as a plastic or metal tin having a lower portion 170and a corresponding or coordinating upper portion 168. A representativehard container 165 is the short, rounded edge, generally cylindricalcontainer traditionally used for the marketing of snus types ofproducts. The hard container 165 is in turn tightly sealed, and canpossess an optional ring or band of a sealing material 195 thatcircumscribes the hard container in the area of the seal between lowerand upper portions 168, 170. As such, conditions are provided so thatthe atmosphere 160 within the hard container 165, can be controlled(e.g., the atmosphere may be composed of high purity nitrogen gas, orother suitable gaseous species). In use, the ring or band of sealingmaterial 195 is broken, the hard container is opened, and individualtobacco portions are removed as desired from the hard container.

Referring to FIG. 5, there is shown a fifth embodiment of arepresentative smokeless tobacco product 110. The tobacco product 110includes several tobacco compositions 115, 140, 141 each contained in asealed, moisture permeable pouch 120, 145, 146, respectively. Eachindividual tobacco portion 156, 157, 158 possesses a sealed outerpackage 125, 211, 212 that surrounds and contains each respectivetobacco portion. Each outer package 125, 211, 212 is tightly sealed, andis selected from an appropriate material, such that the atmosphere 130,221, 222 within each respective outer package can be controlled. Forexample, the atmosphere 130, 221, 222 within each respective outerpackage can be controlled such that the atmosphere is composed of highpurity nitrogen gas, or other suitable gaseous species. If desired, thisembodiment can be altered to provide that each outer package 125, 211,212 contains a plurality (e.g., 2, 3 or 4) of individual tobaccoportions 156, 157, 158. The packaged individual tobacco portions 156,157, 158 are in turn contained within a hard container 165, such as aplastic or metal tin having a lower portion 170 and a corresponding orcoordinating upper portion 168. A representative hard container 165 canbe the short, rounded edge, generally cylindrical containertraditionally used for the marketing of snus types of products. The hardcontainer 165 is in turn tightly sealed, and can possess an optionalring or band of a sealing material 195 that circumscribes the hardcontainer in the area of the seal between lower and upper portions 168,170. As such, conditions are provided so that the atmosphere 160 withinthat hard container 165, is controlled (e.g., the atmosphere is composedof high purity nitrogen gas, or other suitable gaseous species).Alternatively, the hard container 165 can be optionally packaged in asealed outer package 180, such as in the manner previously set forthwith reference to FIG. 3 (e.g., so that the conditions within that outerpackage, and hence within the hard container, are controlled). In eithercase, the modified or controlled atmosphere 160 within hard container165 can be the same or different than the modified or controlledatmospheres 130, 221, 222 of each of the outer packages 125, 211, 212 ofthe individually wrapped tobacco portions 156, 157, 158 (e.g., the hardcontainer can be packaged within an outer package that provides a typeof vacuum seal and the individually wrapped tobacco portions can bewrapped under controlled atmosphere; or the individually wrapped tobaccoportions can be packaged within outer packages that provide a type ofvacuum seal and the outer packaged can be wrapped so as to provideinternal conditions of controlled atmosphere). In use, the outer packageis broken, the hard container is opened, a packaged individual tobaccoportion is removed from the hard container, and that packaged portion isopened so that the tobacco portion can be enjoyed by the consumer.

Referring to FIG. 6, there is shown a sixth embodiment of arepresentative smokeless tobacco product 110. The tobacco product 110may include several tobacco compositions (not shown) each contained in asealed, moisture permeable pouch (not shown). The tobacco compositionsand tobacco portions are of the type previously described with referenceto FIG. 5. Each individual tobacco portion possesses a sealed outerpackage 125, 211, 212 that surrounds and contains each respectivetobacco portion. Each outer package 125, 211, 212 is tightly sealed, andis selected from an appropriate material, such that the atmosphere (notshown) within each respective outer package can be controlled (e.g.,vacuum sealed). In addition, the atmosphere within each respectivepackage can be controlled such that the atmosphere is composed of highpurity nitrogen gas, or other suitable gaseous species. If desired, thisembodiment can be altered so that each outer package 125, 211, 212contains a plurality (e.g., 2, 3 or 4) of individual tobacco portions.The packaged individual tobacco portions within the outer packages 125,211, 212 are in turn connected to one another in an end-to-endrelationship. That is, the individual outer packages 125, 211, 212 eachare “fin sealed” along respective sealing regions 270, 271, 272. The finseal extends longitudinally along the length of each outer package. Forthe embodiment shown, each fin sealed region 270, 271, 272 may possess 5“jaw lines.” At each end of outer package 125, and preferably generallyperpendicular to the longitudinally extending fin seal, are end seals131, 132. In addition, there are comparable end seals for each of theother outer packages. For the embodiment shown, the end seal of eachouter package may possess 3 “jaw lines.” Between adjacent end seals ofeach outer package is a line of perforations 305, 306, 307, such thateach individual package can be separated from the next. A desired numberof the connected outer packages (e.g., 10, 12, 15, 20, 25 or 30) arerolled or wound in a generally spiral manner (e.g., as in a mannergenerally akin to a spool or roll of postage stamps). The resultingwound series of connected outer packages then is positioned within asuitable container 315. One end of the spooled series of outer packagesextends through an opening 320 in the side face of the container 315. Assuch, the container can hold the spooled product, as well as provide amanner or method for dispensing product therefrom. As such, there isprovided a dispenser for an essentially continual strip of smokelesstobacco product (e.g., individual portions of smokeless tobaccocomposition that are connected together but are separable from oneanother about individual tearable lines of perforation).

For the embodiment shown in FIG. 6, the individual packages areconnected in an “end-to-end” type of arrangement. If desired, theconfiguration by which the individual packages can be connected can bealtered. For example, rather than sealing the individual outer packagesat each end of the length of a smokeless product, the smokeless productcan be rotated 90°, and the end seals of the outer package can beparallel to the length of the smokeless product. As such, individualouter packages for smokeless product can be aligned in a “side-by-side”type of arrangement.

For the type of embodiment shown in FIG. 6, individual packages that areconnected to one another in either an “end-to-end” or “side-by-side”type of arrangement can be incorporated into other types of containersfor commercial distribution. For example, a predetermined number (e.g.,4, 5 or 10) of connected but divisible individual outer packages can beincorporated within a package of cigarettes. When incorporated withinthe cigarette package, it is particularly desirable to have thesmokeless product sealed in a controlled atmosphere in order thatflavors and aromas do not migrate as between the cigarettes and thesmokeless product. In this way product integrity is preserved for eachof the jointly packaged products. In one embodiment, cigarettes can bepackaged in a so-called “hard pack”, having a lid that extends upwardbeyond the ends of the cigarettes that are contained therein, and astrip of connected individual packages can be positioned within theinner, upper portion of that lid. Exemplary hard pack designs are setforth in U.S. Pat. No. 4,852,734 to Allen et al.; U.S. Pat. No.5,139,140 to Burrows et al. and U.S. Pat. No. 5,938,018 to Keaveney etal. (For example, a hard pack designed for containing cigarettes havinglengths of about 99 mm in a 7-6-7 configuration can be filled withcomparable cigarettes having lengths of about 85 mm, and severalpackaged smokeless tobacco portions can be contained within the innertop region of the movable top lid). Alternatively, several packagedsmokeless tobacco portions can be included with a cigarette package bycontaining those packaged smokeless portions within the polypropyleneoverwrap that covers the outer regions of the cigarette package.Similarly, packaged smokeless tobacco portions can be connected to acigarette package by adhesive or by fastening as an onsert.

Referring to FIG. 7, there is shown yet another embodiment of arepresentative type of smokeless tobacco product 110. The tobaccoproduct 110 includes a tobacco composition 115 contained in a sealed,moisture permeable pouch 120, thereby providing a tobacco portion 122.The tobacco product 110 possesses a sealed outer package 125 thatsurrounds and contains the tobacco portion 122 in a type of tightlysealed manner. The representative outer package 125 possesses an uppersurface 126 and a lower surface 127. The lower surface 127 is suitablyadapted so as to possess a so-called “blister pack” type of format andconfiguration. As such, the lower surface can have the general shape ofa “bubble” having some degree of structural integrity, and hence can beformed to have a generally hemispherical shape, or other desired shape.The outer package 125 is tightly sealed, and is selected from anappropriate material, such that the atmosphere 130 within that outerpackage is controlled. If desired, the embodiment can be altered inorder that the outer package contains a plurality (e.g., 2, 3 or 4) ofindividual tobacco portions. An edge region 426 about which outerpackage is tightly sealed (e.g., heat sealed) preferably extends aroundthe bubble region of the blister pack. The edge region can form a shapethat is rectangular, square, triangular, hexagonal, circular, or otherdesired shape. If desired, the edge region 426 of each outer package canhave a serrated appearance; can be perforated so as to be connected in astrip or matrix to other outer packages, or can be cut to have thedesired visual effect. Preferably, the length of the inner region of theouter package is at least about 10 percent greater than the overalllength of the tobacco portion, the width of the inner region of theouter package is at least about 10 percent greater than the overallwidth of the tobacco portion, and the height of the inner region of theouter package is somewhat greater than the overall height of the tobaccoportion. For an exemplary embodiment, a snus-type of product has amaximum length of about 30 mm, a width of about 10 mm to about 12 mm,and a height of about 5 mm to about 6 mm; and the outer package has alength of about 40 mm, a width of about 15 mm and a height of 15 mm; andthe end seals of outer package extend around the “bubble” portion at awidth of about 5 mm to about 10 mm. Tobacco product so packaged can beemployed in the general manner set forth previously with reference toFIGS. 1, 2, 5 and 6.

Tobaccos used for the manufacture of tobacco products pursuant to theembodiments herein may vary. The tobaccos may include types of tobaccossuch as flue-cured tobacco, burley tobacco, Oriental tobacco, Marylandtobacco, dark tobacco, dark-fired tobacco and Rustica tobaccos, as wellas other rare or specialty tobaccos. Descriptions of various types oftobaccos, growing practices, harvesting practices and curing practicesare set forth in Tobacco Production, Chemistry and Technology, Davis etal. (Eds.) (1999), which is incorporated herein by reference. See, also,the types of tobaccos that are set forth in U.S. Pat. No. 4,660,577 toSensabaugh, Jr. et al.; U.S. Pat. No. 5,387,416 to White et al.; U.S.Pat. No. 6,730,832 to Dominguez et al.; and U.S. Pat. No. 7,025,066 toLawson et al., and U.S. Pat. Applic. Ser. No. 60/818,198, filed Jun. 30,2006, to Stebbins et al.; each of which is incorporated herein byreference. Most preferably, the tobacco materials are those that havebeen appropriately cured and aged. Especially preferred techniques andconditions for curing flue-cured tobacco are set forth in Nestor et al.,Beitrage Tabakforsch. Int., 20 (2003) 467-475 and U.S. Pat. No.6,895,974 to Peele, which are incorporated herein by reference.Representative techniques and conditions for air curing tobacco are setforth in Roton et al., Beitrage Tabakforsch. Int., 21 (2005) 305-320 andStaaf et al., Beitrage Tabakforsch. Int., 21 (2005) 321-330, which areincorporated herein by reference.

The tobacco used for the manufacture of the tobacco product preferablyis provided in a shredded, ground, granulated, fine particulate orpowder form. The tobacco used for the manufacture of the tobacco productalso can be processed, blended, formulated, combined and mixed withother materials or ingredients. For example, the tobacco composition canincorporate salts, sweeteners, binders, colorants, pH adjusters,fillers, flavoring agents, disintegration aids, antioxidants,humectants, and preservatives. See, for example, those representativecomponents, combination of components, relative amounts of thosecomponents and ingredients relative to tobacco, and manners and methodsfor employing those components, set forth in U.S. patent applicationSer. No. 11/233,399 to Holton, et al. and U.S. patent application Ser.No. 11/351,919 to Holton, et al., each of which is incorporated hereinby reference. For example, the tobacco product can have the form of apouch containing a tobacco composition, and a flavored strip or film;the form of a pouch containing a tobacco composition, and a flavoredstrip or film incorporating finely divided granules of tobacco and/ortobacco extract (e.g., components of a spray dried aqueous extract oftobacco); or the form of a highly processed dissolvable filmincorporating finely divided granules of tobacco and/or tobacco extract.Typically, for certain embodiments, the amount of tobacco materialwithin a portion of an individual portion of a smokeless tobacco can be,on a dry weight basis, at least about 30 mg, often at least about 40 mg,and frequently at least about 45 mg; while that amount typically is lessthan about 200 mg, often less than about 150 mg, and frequently lessthan about 100 mg. The tobacco material can have the form of processedtobacco parts or pieces, cured and aged tobacco in essentially naturallamina or stem form, a tobacco extract, extracted tobacco pulp (e.g.,using water as a solvent), or a mixture of the foregoing (e.g., amixture that combines extracted tobacco pulp with granulated cured andaged natural tobacco lamina).

The moisture content of the tobacco formulation prior to use by aconsumer of the formulation may vary. Typically, the moisture content ofthe tobacco formulation, as present within the pouch prior to insertioninto the mouth of the user, is less than about 55 weight percent,generally is less than about 50 weight percent, and often is less thanabout 45 weight percent. Certain types of tobacco formulations havemoisture contents, prior to use, of less than about 15 weight percent,frequently less than about 10 weight percent, and often less than about5 weight percent. For certain tobacco products, such as thoseincorporating snus-types of tobacco compositions, the moisture contentmay exceed 20 weight percent, and often may exceed 30 weight percent.For example, a representative snus-type product may possess a tobaccocomposition exhibiting a moisture content of about 25 weight percent toabout 50 weight percent, preferably about 30 weight percent to about 40weight percent.

The manner by which the moisture content of the formulation iscontrolled may vary. For example the formulation may be subjected tothermal or convection heating. As a specific example, the formulationmay be oven-dried, in warmed air at temperatures of about 40° C. toabout 95° C., with a preferred temperature range of about 60° C. toabout 80° C. for a length of time appropriate to attain the desiredmoisture content. Alternatively, tobacco formulations may be moistenedusing casing drums, conditioning cylinders or drums, liquid sprayapparatus, ribbon blenders, mixers available as FKM130, FKM600, FKM1200,FKM2000 and FKM3000 from Littleford Day, Inc., Plough Share types ofmixer cylinders, and the like. Most preferably, moist tobaccoformulations, such as the types of tobacco formulations employed withinsnus types of products, are subjected to pasteurization or fermentation.Techniques for pasteurizing or fermenting snus types of tobacco productswill be apparent to those skilled in the art of snus product design andmanufacture.

The pH of the tobacco formulation can vary. Typically, the pH of thatformulation is at least about 6.5, and preferably at least about 7.5.Typically, the pH of that formulation will not exceed about 9, and oftenwill not exceed about 8.5. A representative tobacco formulation exhibitsa ph of about 6.8 to about 8.2. A representative technique fordetermining the pH of a tobacco formulation involves dispersing 2 g ofthat formulation in 10 ml of high performance liquid chromatographywater, and measuring the ph of the resulting suspension/solution (e.g.,with a pH meter).

If desired, prior to preparation of the tobacco formulation, the tobaccoparts or pieces may be irradiated, or those parts and pieces may bepasteurized, or otherwise subjected to controlled heat treatment.Additionally, if desired, after preparation of all or a portion of theformulation, the component materials may be irradiated, or thosecomponent materials may be pasteurized, or otherwise subjected tocontrolled heat treatment. For example, a formulation may be prepared,followed by irradiation or pasteurization, and then flavoringingredient(s) may be applied to the formulation. Alternatively, thetobacco formulation can be irradiated or pasteurized after the tobaccoformulation has been incorporated within a moisture-permeable packet orpouch (e.g., so as to provide individual containers of snus-typesmokeless tobacco product.

The composition/construction of a moisture-permeable packet or pouchthat acts as a snus-type container for use of the tobacco formulationcan vary. Suitable packets, pouches or containers of the type used forthe manufacture of smokeless tobacco products are available under thetradenames “taboka,” CatchDry, Ettan, General, Granit, Goteborgs Rape,Grovsnus White, Metropol Kaktus, Mocca Anis, Mocca Mint, MoccaWintergreen, Kicks, Probe, Prince, Skruf, TreAnkrare, Camel SnusOriginal, Camel Snus Frost and Camel Snus Spice. The tobacco formulationmay be contained in pouches and packaged, in a manner and using thetypes of components used for the manufacture of conventional snus typesof products. The pouch or fleece provides a liquid-permeable containerof a type that may be considered to be similar in character to themesh-like type of material that is used for the construction of a teabag. Components of the loosely arranged, granular tobacco formulationreadily diffuse through the pouch and into the mouth of the user.

Descriptions of various components of snus types of products andcomponents thereof also are set forth in U.S. Pat. App. Pub. No.2004/0118422 to Lundin et al., which is incorporated herein byreference. See, also, for example, U.S. Pat. No. 4,607,479 to Linden;U.S. Pat. No. 4,631,899 to Nielsen; U.S. Pat. No. 5,346,734 to Wydick etal.; and U.S. Pat. No. 6,162,516 to Derr, and U.S. Pat. App. Pub. No.2005/0061339 to Hansson et al.; each of which is incorporated herein byreference. See, also, the representative types of pouches, and pouchmaterial or fleece, set forth in U.S. Pat. No. 5,167,244 to Kjerstad,which is incorporated herein by reference. Snus types of products can bemanufactured using equipment such as that available as SB 51-1/T, SBL 50and SB 53-2/T from Merz Verpackungmaschinen GmBH. Snus pouches can beprovided as individual pouches, or a plurality of pouches (e.g., 2, 4,5, 10, 12, 15, 20, 25 or 30 pouches) can connected or linked together(e.g., in an end-to-end manner) such that a single pouch or individualportion can be readily removed for use from a one-piece strand or matrixof pouches.

Although the tobacco composition most preferably is provided in a formthat is characteristic of a snus type of product, the tobaccocomposition also can have the form of loose moist snuff, loose drysnuff, chewing tobacco, pelletized tobacco pieces, extruded tobaccostrips or pieces, finely divided ground powders, finely divided ormilled agglomerates of powdered pieces and components, flake-like pieces(e.g., that can be formed by agglomerating tobacco formulationcomponents in a fluidized bed), molded processed tobacco pieces, piecesof tobacco-containing gum, products incorporating mixtures of ediblematerial combined with tobacco pieces and/or tobacco extract, productsincorporating tobacco (e.g., in the form of tobacco extract) carried bya solid inedible substrate, and the like. For example, the tobaccocomposition can have the form of compressed tobacco pellets,multi-layered extruded pieces, extruded or formed strands, rods orsticks (for example, a strand, rod or stick having a length of about 3-7centimeters, preferably about 4-6 centimeters, and a diameter of about1-5 millimeters, preferably about 2-4 millimeters), compositions havingone type of tobacco formulation surrounded by a different type oftobacco formulation, rolls of tape-like films, readily water-dissolvableor water-dispersible films or strips, or capsule-like materialspossessing an outer shell (e.g., a pliable or hard outer shell that canbe clear, colorless, translucent or highly colored in nature) and aninner region possessing tobacco or tobacco flavor (e.g., a Newtoniamfluid or a thixotroic fluid incorporating tobacco of some form).

Processed tobacco compositions, such as compressed tobacco pellets canbe produced by compacting granulated tobacco and associated formulationcomponents, compacting those components in the form of a pellet, andoptionally coating each pellet with an overcoat material. Exemplarygranulation devices are available as the FL-M Series granulatorequipment (e.g., FL-M-3) from Vector Corporation and as W120V and WP200VN from Alexanderwerk, Inc. Exemplary compaction devices, such ascompaction presses, are available as Colton 2216 and Colton 2247 fromVector Corporation and as 1200i, 22001, 3200, 2090, 3090 and 4090 fromFette Compacting. Devices for providing outer coating layers tocompacted palletized tobacco formulations are available as CompuLab 24,CompuLab 36, Accela-Cota 48 and Accela-Coata 60 from Thomas Engineering.

Processed tobacco compositions, such as multi-layered tobacco pellets,can be manufactured using a wide variety of extrusion techniques. Forexample, multi-layered tobacco pellets can be manufactured usingco-extrusion techniques (e.g., using a twin screw extruder). In such asituation, successive wet or dry components or component mixtures can beplaced within separate extrusion hoppers. Steam, gases (e.g., ammonia,air, carbon dioxide, and the like), and humectants (e.g., glycerin orpropylene glycol) can be injected into the extruder barrel as each drymix is propelled, plasticized, and cooked. As such, the variouscomponents are processed so as to be very well mixed, and hence, come incomplete contact with each other. For example, the contact of componentsis such that individual components can be well embedded in the extrusionmatrix or extrudate. See, for example, U.S. Pat. No. 4,821,749 to Toftet al., which is incorporated herein by reference.

Certain tobacco compositions can incorporate tobacco as the majorcomponent thereof. Preferably, those compositions do not, to anysubstantial degree, leave any residue in the mouth of the user thereof.Preferably, those compositions do not provide a the user's mouth withslick or slimy sensation (e.g., due to overly high levels of bindingagents). Tobacco materials, during processing, can be treated with pHadjusters or other suitable agents, so that natural pectins within thetobacco material can be released. Release of natural tobacco pectin canact to reduce the amount of additional gums/hydrocolloids,cellulose-derived, or starch-based binders needed to aid in desiredsheet or film tensile strength qualities. For example, to releasepectin, fine tobacco powder is cooked in an alkaline pH adjustedsolution at elevated temperatures relative to ambient. Such treatmentalso can provide desirable sensory attributes to the tobacco material.See, for example, U.S. Pat. No. 5,099,864 to Young et al.; U.S. Pat. No.5,339,838 to Young et al. and U.S. Pat. No. 5,501,237 to Young et al.;which are incorporated herein by reference.

One representative type of individual portion tobacco product possessesan outer shell and an inner region in the form of a tobacco formulation.A representative outer shell can be provided by providing a liquidmixture of alginates (e.g., sodium alginates available as Kelvis, Kelginand Mannucol from International Specialty Products Corp.), rice starch,sucralose, glycerin and flavoring agent (e.g., mint flavor) in water soas to provide a liquid mix exhibiting a Brookfield viscosity at 25° C.of about 20,000 to about 25,000 centipoise. That viscous mixture can beused to form a sheet that can be formed into an outer layer (e.g., usinga Villaware Imperia Pasta Machine, Dough Roller 150 equipped with aVillaware Ravioli Attachment for Imperia 150-25, each of which isavailable through Imperia Trading Company) or semi-circular shells thatcan be combined (e.g., by exposure to heat) to form an outer layer.Typically, such a viscous mixture can be suitably dried by heating atabout 60° C. for about 1 hour. Inside that outer shell can beincorporated a wide variety of tobacco formulations. One representativetobacco formulation used as the inner region of such a is a dry or moistmixture of granulated or milled tobacco material that can be mixed withother ingredients, such as flavoring agents, humectants, emulsifiers,fillers, pH adjusters, dispersion aids, and the like. One representativetobacco formulation has the form of a fluid (e.g., the form of a weakgel or soft gel). That tobacco formulation can be provided by mixinggranulated or milled tobacco material, kappa-carageenan, Kelvis-typesodium alginate, propylene glycol, polysobate 60, and flavoring agent(e.g., menthol and cinnamon) in water, such that the moisture content ofthe formulation is about 40 to about 50 weight percent. Onerepresentative tobacco formulation has the form of a fluid. That tobaccoformulation can be provided by mixing granulated or milled tobaccomaterial, glycerin, glycerol stearate, propylene glycol,kappa-carageenan, carboxymethycellulose available as Ticalose 1500 fromTIC Gums and micro-crystalline cellulose (e.g., Ticacel HV from TICGums) in water, such that the moisture content of the formulation isabout 60 to about 70 weight percent.

The amount of tobacco formulation incorporated within each sealed outerpackage can vary. In one aspect, loose tobacco composition can beincorporated into an outer package, the package is sealed, and thatloose tobacco can be used as loose snuff or chewing tobacco when theouter package is opened. In another, but preferred, aspect, tobaccocomposition contained within a snus-type pouch or packet is incorporatedwithin the outer package, the package is sealed, and the snus-typeproduct can be used when the outer package is opened. Typically, theamount of tobacco formulation within each individual portion (e.g.,within each snus-type pouch) is such that there is at least about 50 mg,often at least about 150 mg, and frequently at least about 250 mg, ofdry weigh tobacco; and less than about 700 mg, often less than about 500mg, and frequently less than about 300 mg, of dry weight tobacco. Forexample, snus-type smokeless tobacco products can have the form ofso-called “portion snus.”

One exemplary snus-type product possesses about 1 g of a tobaccoformulation having a moisture content of about 35 weight percent; whichtobacco formulation is contained in a sealed fleece pouch having anoverall length of about 30 mm, a width of about 16 mm, and a height ofabout 5 mm, wherein the length of the compartment area of that pouch isabout 26 mm due to a seal of about 2 mm width at each end of that pouch.Another exemplary snus-type product possesses about 0.5 g of a tobaccoformulation having a moisture content of about 35 weight percent; whichtobacco formulation is contained in a sealed fleece pouch having anoverall length of about 26 mm, a width of about 12 mm, and a height ofabout 5 mm, wherein the length of the compartment area of that pouch isabout 22 mm due to a seal of about 2 mm width at each end of that pouch.

The outer packaging material useful in accordance with the presentinvention can vary. Typically, the selection of the packaging materialis dependent upon factors such as aesthetics, comfort of handling,desired barrier properties (e.g., so as to provide protection fromexposure to oxygen or radiation, or so as to provide protection fromloss of moisture), or the like. The packaging material most preferablyhas the form of a film, such a laminated film (e.g., a co-extrudedlaminated film). The number of layers present with a laminated packagingmaterial can vary; and can be at least about 3 layers, and often atleast about 4 layers; while typically, the number of layers does notexceed about 10 layers, and often does not exceed about 8 layers.Overall thicknesses of exemplary packaging materials typically are atleast about 0.0025 inch, often at least about 0.003 inch; whiletypically, the thickness of the packaging materials typically is lessthan about 0.006 inch, and often less than about 0.005 inch.Representative materials that can be used to provide components orlayers of film materials or laminated films can include polyvinylchloride, ethylene vinyl acetate co-polymer, oriented polypropylene,linear low density polyethylene, polyvinylidene dichloride, polyesterterephalate, ethylene methacrylic acid co-polymer, metallacene linearlow density polyethylene, and the like. Exemplary packaging materialscan be plastic/metal films, plastic/metal films that are paper coated,plastic laminate films, or the like. Such types of materials can bemanufactured from materials that make them essentially impervious tooxygen and/or moisture, can be sealed to provide a seal with goodintegrity, and can provide an outer package that retains or maintainsits impervious nature or character over time. Suitable materials are ofthe type that have been employed as packaging materials for thecontrolled atmosphere or vacuum packaging of food and pharmaceuticaltypes of products.

Exemplary other materials useful form providing packaging materials ofthe present invention preferably include flexible-type plasticmaterials. See, for example, those polymeric materials, sealants,adhesives, and the like, set forth in US Pat. Pub. No. 2004/0043165 toVan Hulle et al.; which is incorporated herein by reference. Forpackaging materials that are used for the purpose of preventingcontamination of the tobacco composition by oxygen, it is desirable toincorporate an effective amount of suitable reducing agent into thematerial that provides the inner surface of the packaging material.

One exemplary laminated film possesses four layers; the top or outerlayer being composed of a layer of polyester terephalate (PET) having athickness of about 0.00048 inch, a thin layer of adhesive (e.g., apolyurethane-type adhesive available under the tradename Tycel from theLiofol Company), a metal film (e.g., aluminum) having a thickness ofabout 0.00035 inch, and a bottom layer of an ethylene methacrylic acidcontaining composition available under the tradename Surlyn from E. I.DuPont de Nemours & Company and having a thickness of about 0.002 inch.If desired, the side of the PET adjacent the adhesive can be printedwith product information using a suitable ink. Another exemplarylaminated film possesses three layers; the top or outer layer beingcomposed of a layer of PET having a thickness of about 0.00048 inch, athin layer of adhesive (e.g., an adhesive available as Tycel), and abottom layer of a composition available as Surlyn and having a thicknessof about 0.002 inch. Another exemplary laminated film possesses fourlayers; the top or outer layer being composed of a layer of PET having athickness of about 0.00048 inch, a thin metal film (e.g., aluminum), athin layer of adhesive (e.g., an adhesive available as Tycel), and abottom layer composition available as Surlyn and having a thickness ofabout 0.002 inch. The foregoing representative types of laminated filmsare suitable for providing so-called “fin sealed” and “three-sided”types of packaging containers having the PET layer as the outer surfaceof those containers.

One exemplary laminated film possesses; the top or outer layer beingcomposed of a layer of a material such as Surlyn having a thickness of0.002 inch, a thin layer of adhesive, a metal film (e.g., aluminum)having a thickness of about 0.00035 inch, a thin layer of adhesive, anda bottom layer of a material such as Surlyn having a thickness of about0.002 inch. The foregoing representative type of laminated film issuitable for providing so-called “lap seal” types of pouches.

The present invention can involve the use of equipment, materials,methodologies and process conditions that are suitably modified in orderto provide the packaging and controlled atmospheric conditions for thetobacco products that are packaged pursuant thereto. The atmospherewithin the packaging materials can be modified in a variety of ways. Forexample, a significant amount of the atmosphere within the package canbe removed (e.g., by using vacuum packaging types of techniques), or theatmosphere within the package can be altered in a controlled manner(e.g., by using gas flushing types of techniques). Representativeaspects of various technologies associated with modified atmospherepackaging and controlled atmosphere packaging are set forth in Analysisand Evaluation of Preventative Control Measures for the Control andReduction/Elimination of Microbial Hazards on Fresh and Fresh-CutProduct; Chapter VI; Microbiological Safety of Controlled and ModifiedAtmosphere Packaging of Fresh and Fresh-Cut Product; U.S. Food and DrugAdministration, Center for Food Safety and Applied Nutrition (Sep. 30,2001); which is incorporated herein by reference.

The controlled or modified atmospheres within packaged tobacco productsof the present invention can vary. Typically, when tobacco product isvacuum packed or flushed so as to have a controlled or modifiedatmosphere (e.g., even if the atmosphere is controlled in a manner suchthat the atmospheric pressure within the sealed package is at a positivepressure relevant to ambient atmospheric pressure), atmosphericconditions within the package are controlled such that a significantamount, and most preferably virtually all of the oxygen present withinwith package, is removed from that package prior to the time that thepackage is sealed. That is, less than about 8 percent, and often lessthan about 6 percent, of the weight of the controlled atmosphereinitially present with a sealed outer package is composed of oxygen. Forexample, when the package is sealed, the atmosphere present within thepackage preferably can possess less than about 5 percent oxygen, andmost preferably between about 1 percent oxygen and about 5 percentoxygen, based on the weight of the controlled atmosphere initiallypresent within that sealed package. Typically, when the tobacco productis flushed with a gaseous species (e.g., a selected gas or mixture ofgases), a significant amount, and most preferably virtually all, of theatmosphere within the sealed package is provided by the desired gaseousspecies. Exemplary gaseous species include nitrogen, argon, carbondioxide, and the like (e.g., high purity gases that are greater thanabout 99 percent pure, by weight). Alternatively, the atmosphere towhich the tobacco product incorporates a relatively high level of adesired gaseous species (e.g., oxygen) in order to introduce the effectsof “gas shock” to the tobacco product (e.g., relatively high levels ofoxygen in the atmosphere can be desirable for the introduction of“oxygen shock” for purposes of inhibiting enzymatic discoloration,preventing anaerobic fermentation reactions, and inhibiting aerobic andanaerobic microbial growth). For example, a controlled atmospherecontaining an amount of oxygen such that the level of oxygen in thatatmosphere greater than about 25 percent by weight, often greater thanabout 30 percent by weight, can provide conditions suitable forintroduction of oxygen shock.

Representative equipment useful for carrying out process stepsassociated with the packaging aspects of the present invention isavailable from Winpak Ltd. (eg., systems identified as LD32, L25, L18and L12); as Linium 300 Series horizontal flow wrapping systems fromDoboy Inc. (e.g., Linium Model Nos. 301, 302, 303, 304 or 305); asHiwrap 504 systems available from Hitech Systems s.r.l.; and as thetypes of systems available from Rovema Verpackungmaschinen GmbH.Preferred equipment provides a wrapping material that provides a sealthat does not allow passage of gases or moisture therethrough (e.g., aseal that might be considered as “air tight”).

Representative blister pack packaging materials can vary. Exemplarymaterials used for the lower layer of a typical blister pack packagingmaterial are laminated polymer films available as Pentapharm alfoilT-250/25/90, Pentapharm ACLAR PA 180/02, Pentapharm ACLAR PA 200/02, andPentapharm ACLAR PA 300/02, from Klockner-Pentaplast of America, Inc.Exemplary materials used for the upper layer of a typical blister packpackaging material are heat sealable metal films. An exemplary heatsealable film is an aluminum film having a thickness of about 0.0007inch coated on the sealing side with a heat sealable material (e.g.,Surlyn) that has a thickness of about 0.0001 inch. See, also, forexample, the types of materials set forth in US Pat. Pub. No.2004/0043165 to Van Hulle et al.; which is incorporated herein byreference. Although so-called “pealable lid” types of blister packagescan be employed, off particular interest are the so-called “pushthrough” types of blister packages.

If desired, the packaging can be carried out in a controlledenvironment. That is, pasteurized tobacco product can be packaged inouter packages in a sterile environment.

Products of the embodiments herein may be packaged and stored in muchthe same manner that conventional types of smokeless tobacco productsare packaged and stored. For example, a plurality of packets or pouchesmay be contained in a cylindrical container. If desired, moist tobaccoproducts (e.g., products having moisture contents of more than about 20weight percent) may be refrigerated (e.g., at a temperature of less thanabout 10° C., often less than about 8° C., and sometimes less than about5° C.). Alternatively, relatively dry tobacco products (e.g., productshaving moisture contents of less than about 15 weight percent) often maybe stored under a relatively wide range of temperatures.

For preferred embodiments herein, smokeless tobacco composition ispackaged in such a manner that there is no requirement for the necessityof refrigeration during periods of transport and prior to sale. That is,shipping, handling and storage can be simplified, and the periods duringwhich shipping, handling and storage are carried out can be prolonged,while the quality of the smokeless product can be maintained. Inaddition, though the shelf life of the product can be prolonged, thusnegating the necessity of refrigeration, the shelf life of refrigeratedproduct also can be prolonged. Product packaged in accordance with theembodiments herein can be stored for prolonged periods of time, whilemaintaining its overall freshness, maintaining its moisture content,maintaining its visual appearance (e.g., not undergoing significantdiscoloration), maintaining its sensory properties, not experiencingabsorption of undesirable flavors or odors, and not undergoing change inits overall chemical nature due to the action of microbial species.Moist tobacco product (e.g., products having moisture contents of morethan about 20 weight percent, and often more than about 30 weightpercent) can be stored for prolonged periods of time without thenecessity of refrigeration.

The following examples are provided to illustrate further certainaspects of the embodiments herein, but should not be construed aslimiting the scope thereof. Unless otherwise noted, all parts andpercentages are by weight.

EXAMPLE 1

A tobacco formulation in the form of a somewhat flat strip or film isprovided in the following manner.

Tobacco material, comprised of a mixture of cured and aged flue-cured,burley and Oriental lamina is provided in a strip or leaf form, and at amoisture of about 9 percent. A portion of this tobacco mixture is washedwith water, and the solubles or extractable portion that is collected isdiscarded, and the remaining water insoluble solids (e.g., pulp portion)is dried. The resulting dried pulp portion then is mixed with theretained untreated portion of the original tobacco mixture. That tobaccomixture then is milled to a particle size that passes through a 150Tyler mesh screen.

The resulting tobacco mixture is further mixed with other ingredients toform the a formulation that contains about 40 parts of milled tobaccolamina, about 25 parts calcium carbonate, about 15 parts binder (whichmay be composed of pectin, gelatin, sodium alginate and starch), about15 parts glycerin, about 4 parts flavoring, and about 1 part sucraloseor about 1 part sweetening agent available as SucraSweet HIS 600 fromSweetener Solutions LLC (on a dry weight basis). The binder can be asuitable binding agent (e.g., food grade type binding agent), andexemplary binding agents can be selected from a variety of pectins,gelatins, alginates (e.g., sodium alginate) or starches. The resultingdry mixture is dispersed in deionized water (e.g., about 8 to about 10parts dry mixture in about 90 to about 92 parts water) to form a slurrythat exhibits a Brookfield viscosity of about 20,000 centipoise to25,000 centipoise at 25° C.

The slurry is cast as a thick, uniform layer onto a stainless steeldrying tray, which can be lightly coated with a non-stick spray beforecasting the slurry. The tray is placed in a drying oven at relativelylow heat (e.g., about 60° C. to about 70° C.) for up to about 10 hours(e.g., about 6 to about 8 hours). As such, a formed mixture of tobaccoformulation components is provided in a desired shape from an aqueousslurry of those components.

The slurry can be cast in the shape of a strip (e.g., having a length ofabout 25 cm to about 35 cm) and a width of about 1 cm to about 2 cm. Ifdesired, optional perforation or weakness lines that extend generallyperpendicular to the longitudinal axis of the strip can be stamped intothe strip at predetermined intervals. The resulting product, which canbe formulated and dried so as to be pliable and possess an acceptablyhigh tensile strength, can be coiled and incorporated within the type ofcontainer described previously with reference to FIG. 6. That containerthen can be packaged within an outer package, and under controlledatmospheric conditions, of the general type described previously. Inuse, the outer package can be opened, and a piece of the long strip oftobacco formulation extending from an opening on the container can bebroken off in the desired amount for use.

The slurry can be cast as a sheet or film, and upon drying, individualportions can be stamped, punched or cut from that sheet or film. Thus,for example, rectangular strips or sheets, or circular pieces can beprovided from the sheet or film; and packaged as individual portions(e.g., using outer wrapping material configured in the general mannerdescribed previously with reference to FIG. 1).

Cast material that has been dried can be ground into a powder orgranulated form, and then packed within a moisture permeable pouch andsealed. Each such pouch can be packaged in an outer package, in themanner described previously with reference to FIG. 1.

EXAMPLE 2

The smokeless tobacco products that are preferably non-chewable tobaccoproducts that are intended to be placed between the cheek and the gum ofthe mouth are provided as follows. Preferred smokeless tobacco products,when used orally, completely dissolve in the mouth leaving little to nosolid or granular residue, while dispensing or dispersing tobaccocomponents, and while providing a pleasant trigeminal and organolepticexperience.

Cured and/or aged tobacco lamina or stems is provided in a strip orshredded form, and at a moisture content of about 9 percent, or less.Tobacco types can include flue-cure, burley and Oriental tobaccos, andvarious combinations thereof. In addition, specialty or exotic types oftobaccos, including tobaccos such as Perique and Cavendish, also can beincorporated within blends of tobacco materials. The lamina or stem ismilled under cryogenic conditions, or any other suitable dry millingmeans, to a fine ground form. The powder is sufficiently fine so as topass through a 150 Tyler mesh screen. The resulting powder then isirradiated with about 5 to about 20 kilo Grays of gamma radiation.

Flue cured tobacco lamina that has been aged is provided in a stripform, and at a moisture content of about 9 percent or less. The laminais milled under cryogenic conditions or any other suitable dry millingmeans to a fine ground form. The powder is sufficiently fine so as topass through a 150 Tyler mesh screen. The resulting powder then isirradiated with about 5 to about 20 kilo Grays of gamma radiation.

The tobacco powder is introduced into a fluidized bed. While in thefluidized bed, the tobacco powder is introduced to a mixture of waterand various other ingredients that have been provided in a dry powderform. The resulting mixture is removed from the fluidized bed, and driedto a moisture content of about 4 percent.

The resulting tobacco formulation is removed from the fluidized bed. Arepresentative formulation contains about 25 to about 40 parts of thegranulated flue-cured tobacco lamina, about 0.5 to about 3.0 parts ofsucralose (modified sugar), about 1 part titanium dioxide (colormodifier), about 10 to about 25 parts calcium carbonate (in the formavailable as HD PPT Fine from Ruger Chemical), about 15 to about 30parts mannitol powder, about 2 to about 5 parts powdered cellulose (inthe form available as QC-90 from CreaFill Fibers), about 5 to about 15parts pregelatinized corn starch (in the form available as Starch 1500from Colorcon), about 3 to about 6 parts povidone (in the form availableas PVPK-30 from Xian Medicines & Health Products), and about 0.75 toabout 2.5 parts potassium hydroxide. The moisture content of theresulting granulated tobacco formulation is about 4 percent. Theresultant granulated tobacco formulation is a dry, free flowing, finelymilled powder that is light tan in color, and is made up of particleshaving an average particle size sufficient to pass through a screen ofabout 80 Tyler mesh.

A desired amount of the tobacco formulation (e.g., about 0.5 g to about1 g) of the tobacco formulation can be placed within a sealed fleecepouch, and that pouch can be packaged within an outer package, such asin the general manner set forth previously with reference to FIG. 1.

EXAMPLE 3

A dry mix of about 200 g to about 225 g of granulated tobacco powder ofthe type described previously in Example 2, a flavoring agent (e.g.,mint flavor) and optionally sodium chloride are mixed for about 5minutes in a table-top Model P400 Popiel™ Automatic Pasta Maker(available from Ronco Inventions, LLC, Chestworth, Calif.). Then, about48 g portion of a premixed warm aqueous solution (e.g., about 40 g waterand about 8 g glycerin) is added to the dry mix. Those contents aremixed for about 3 minutes, or until small pea-like size lumps develop.The pea-like mixture is subsequently extruded via selected dies toobtain flat pasta-like sheets (1.4 cm wide×30 cm length×0.1 to 0.7 cmdepth) or noodle-like cylindrical rods (0.1 to 0.7 cm diameter ×12 to 24cm length). The pasta-like sheet is further cut into smaller square orrectangular pieces to obtain pellets that each weigh about 185 mg toabout 250 mg. Generally wafer shaped pieces, each weighing about 185 mgto about 250 mg, also can be punched out of the pasta-like sheets. Thenoodle-like rods are further cut to obtain smaller cylindrical pelletpieces or strands, each weighing about 185 mg to about 250 mg. Generallywafer shaped pieces (e.g., generally cylindrically shaped pieces), eachweighing about 185 mg to about 250 mg, also can be cut from extrudedcylindrical rods (e.g., a continuous cylindrical extrudate can be cutgenerally perpendicular to its longitudinal axis). Alternatively, thincylindrical extrudate can be similarly subdivided to provide somewhatlonger, stick-like pieces that weight about 150 mg to about 250 mg. Thevarious shaped pieces are placed onto a stainless steel plate and driedby ambient temperatures for up to about 24 hours (e.g., for about 12 toabout 20 hours). Alternatively, the pieces are dried either via forcedair ovens operated at about 50° C. to about 100° C. for up to 15minutes, or over steam from boiling water baths. The dried productstypically exhibit moisture contents of about 5 to about 10 percent.Typical tobacco formulations exhibit, on a dry weight basis, about 85 toabout 99 parts of the granulated tobacco powder, about 1 to about 15parts flavoring agent, and about 1 to about 1.5 parts optional sodiumchloride.

The various tobacco formulations can be packaged in the manner set forthpreviously with reference to FIG. 1 through FIG. 5 and FIG. 7.

EXAMPLE 4

Tobacco formulations having the general size and shape of those setforth previously in Example 3 are provided, using the types ofpreparation techniques set forth in Example 3. However, the granulatedtobacco powder that is employed in Example 3 is replaced with a finelymilled tobacco powder that is prepared as follows.

Flue cured tobacco lamina that has been aged is provided in a stripform, and at a moisture content of about 9 percent or less. The laminais milled under cryogenic conditions or any other suitable dry millingmeans to a fine ground form. The powder is sufficiently fine so as topass through a 150 Tyler mesh screen. The resulting powder then isirradiated with about 5 to about 20 kilo Grays of gamma radiation.

The powdered tobacco lamina and various other dry ingredients arepremixed in an automated tumbling mixer for about 15 minutes. As such,on a dry weight basis, a dry mix is prepared from about 122.5 g of thetobacco powder, about 80.5 g cane sugar, about 52.5 g precipitatedcalcium carbonate, about 17.5 g mannitol, about 48 g rice starch(pregelatinized) and about 1.7 g vanilla flavoring. Then, that dry mixis combined with about 100 g of warm water (e.g., at about 30° C. toabout 45° C.) having about 4.6 g of potassium hydroxide dissolvedtherein in the pasta maker described in Example 3.

Tobacco formulations of the type generally set forth in Example 3 areprovided. That is, the tobacco formulations can be formed into desiredshapes, such as sheets, strips, pellets, sticks, and the like. Theshaped tobacco formulations can be packaged using the types of outerpackaging materials set forth hereinbefore.

EXAMPLE 5

Tobacco formulations are provided in the manner set forth previously inExample 4. However, the tobacco formulation ingredients are formulatedas follows. The powdered tobacco lamina described in Example 4, andvarious other dry ingredients are premixed in an automated tumblingmixer for about 15 minutes. As such, on a dry weight basis, a dry mix isprepared from about 60 g of the tobacco powder, about 50 g cane sugar,about 34 g precipitated calcium carbonate, about 20 g mannitol, about 20g rice starch (pregelatinized), about 10 g maltodextrin, about 5.2 gmicrocrystalline cellulose (available as Ticacel HV from TIC Gums),about 0.8 g vanilla flavoring, about 0.5 g menthol and about 3.5 gglycerol tristearate. Then, that dry mix is combined with about 50 g ofwarm water (e.g., at about 30° C. to about 45° C.) having about 2 g ofpotassium hydroxide dissolved therein in the pasta maker described inExample 3.

EXAMPLE 6

Tobacco formulations are provided in the manner set forth previously inExample 4. However, the tobacco formulation ingredients are formulatedas follows. A powdered tobacco lamina is provided from flue-cured andburley tobacco lamina, in the general manner set forth in Example 4. Inaddition, in the general manner set forth in Example 4, that powderedtobacco lamina, and various other dry ingredients are premixed in anautomated tumbling mixer for about 15 minutes. As such, on a dry weightbasis, a dry mix is prepared from about 64 g of the tobacco powder,about 4.4 g of a sweetening agent available as SucraSweet HIS 600 fromSweetener Solutions LLC, about 40 g precipitated calcium carbonate,about 42 g mannitol, about 19 g rice starch (pregelatinized), about 9 ghydroxypropylmethylcellouse available as Klucel EF from Hercules, Inc.and about 5 g microcrystalline cellulose (available as Ticacel HV fromTIC Gums). Then, that dry mix is combined with about 50 g of warm water(e.g., at about 30° C. to about 45° C.) having about 2.5 g of potassiumhydroxide and about 8 g glycerin dissolved therein in the pasta makerdescribed in Example 3.

EXAMPLE 7

Tobacco formulations are provided in the manner set forth previously inExample 4. However, the tobacco formulation ingredients are formulatedas follows. A powdered tobacco lamina is provided from flue-cured andburley tobacco lamina, in the general manner set forth in Example 4. Inaddition, in the general manner set forth in Example 4, that powderedtobacco lamina and various other dry ingredients are premixed in anautomated tumbling mixer for about 15 minutes. As such, on a dry weightbasis, a dry mix is prepared from about 64 g of the tobacco powder,about 4.4 g of a sweetening agent available as SucraSweet HIS 600 fromSweetener Solutions LLC, about 40 g precipitated calcium carbonate,about 42 g mannitol, about 19 g rice starch (pregelatinized), about 9 gsodium alginate available as Kelvis from International SpecialtyProducts Corp., about 2 g of mint flavoring agent and about 5 gmicrocrystalline cellulose (available as Ticacel HV). Then, that dry mixis combined with about 40 g of warm water (e.g., at about 30° C. toabout 45° C.) having about 2.5 g of potassium hydroxide and about 8 gglycerin dissolved therein in the pasta maker described in Example 3.

EXAMPLE 8

A tobacco composition having the form of a multi-layered,multi-flavored, co-extruded pellet is provided as follows.

Granulated tobacco powder and other dry ingredients are again used asdescribed in Example 1, to make a two layered pellet smokeless tobaccoformulation. The pellet can be characterized as having a shape thatmight be considered to “pillow-type” in nature (i.e., the top, bottom,sides and ends are made up by the outer layer or over layer, and theinner layer is contained within the outer layer).

The inner layer is provided by mixing about 200 g granulated flue-curedtobacco powder, about 6 g sodium chloride and about 1.5 g mentholpowder. Then, that dry mix is combined with about 42 g of warm water(e.g., at about 30° C. to about 45° C.) having about 8 g of glycerindissolved therein in the pasta maker described in Example 3. The innerlayer is generally cylindrical and is made as noodle-like rod.

The outer layer is provided by mixing about 200 g granulated flue-curedtobacco powder, about 5 g sodium chloride and about 14 g of a finelymilled burley tobacco powder. The outer layer is made as a pasta-likeflat sheet containing more fine tobacco powder, as but less flavoringagent than the inner layer.

To make the smokeless tobacco composition, the pasta-like sheet iswrapped completely around the thin noodle-like rod. The enwrapped rod isthen cut into smaller cylindrical pellets, and both cut ends molded orsealed to form small pillow-like pellets, each pellet weighing about 185mg to about 250 mg. The pellets are ambient temperature dried over about12 hours, or dried for about 20 minutes in a forced air oven set atabout 50° C. to about 80° C.

It will be understood that the inner and outer layers may be formulatedin various ways; for example one layer may be produced to differ fromthe other in its level of tobacco sensory properties, such as by varyingthe level of flavorings or by using differing mixtures of tobaccocompositions or formulations. Moreover, in addition to co-extrusion, themulti-layering can also be achieved by physically wrapping a preformedouter layer around a preformed inner layer. Alternatively, an innerlayer portion may be laminated between two outer layer portions ofslightly larger lateral dimensions, and the outer layers may then besealed together at their edges to envelop the inner layer.

The tobacco formulation so formed can be packaged within an outerpackage of the type described previously with reference to FIG. 1.

EXAMPLE 9

A tobacco composition having the general form of a tape or roll isprovided as follows.

Fine tobacco powder containing a mixture of flue-cure and burley ispremixed in a tumbling mixer for 15 minutes with other ingredients. Assuch, a dry mix that is provided contains about 60 g granulated tobaccomaterial, about 3.4 g of a sweetening agent available as SucraSweet HIS600, about 36 g precipitated calcium carbonate, about 40 g mannitol,about 20 g rice starch (pregelatinized), about 10 g sodium alginateavailable as Kelvis from International Specialty Products Corp., about 3g of menthol flavor, about 5 g cinnamon flavor and about 4 gmicrocrystalline cellulose (available as Ticacel HV). Then, that dry mixis combined with about 42 g of warm water (e.g., at about 30° C. toabout 45° C.) having about 8 g of glycerin and about 2.6 g potassiumhydroxide dissolved therein in the pasta maker described in Example 3.The aqueous solution is then gently added to the dry mix in the pastamaker and mixed for 3 minutes or until pea-like size lumps are formed.The blend is then extruded into flat pasta-like sheets of dimensionabout 1.4 cm wide by about 30 cm long, by about 0.1 cm to about 0.3 cmthick. Each sheet is further perforated at intervals of about 0.5 toabout 1.5 cm intervals length-wise to obtain a roll or tape-like productfrom which square or rectangular pieces can easily be cut off Samplesare preferably not fully dried; and hence, maintain prolongedpliability, elasticity, and tensile strength. The moisture content ofthe tobacco composition ranges from about 12.5 to about 25 percent.

The tape-like product can be formed into a roll, and positioned withinan outer container of the type described previously with reference toFIG. 6. That outer container then can be wrapped with an outer wrappingmaterial, using packaging conditions such as those of the type describedhereinbefore.

EXAMPLE 10

A tobacco composition having the general form of a tape or roll isprovided as follows.

Fine tobacco powder containing a mixture of flue-cure and burley ispremixed in a tumbling mixer for 15 minutes with other ingredients. Assuch, a dry mix that is provided contains about 52 g granulated tobaccomaterial, about 2 g of a sweetening agent available as SucraSweet HIS600, about 30 g precipitated calcium carbonate, about 27.5 g rice starch(pregelatinized), about 40 g sodium alginate available as Manucol LDfrom ISP Corporation, about 12 g sodium alginate available as Kelvisfrom ISP Corporation, about 3 g of menthol flavor, about 5 g cinnamonflavor and about 4 g microcrystalline cellulose (available as TicacelHV). Then, that dry mix is combined with about 40 g of warm water (e.g.,at about 30° C. to about 45° C.) having about 16 g of glycerin and about7 g sodium carbonate dissolved therein in the pasta maker described inExample 3. The aqueous solution is then gently added to the dry mix inthe pasta maker and mixed for 3 minutes or until pea-like size lumps areformed. The blend is then extruded into flat pasta-like sheets ofdimension about 1.4 cm wide by about 30 cm long, by about 0.1 cm toabout 0.3 cm thick. Each sheet is further perforated at intervals ofabout 0.5 to about 1.5 cm intervals length-wise to obtain a roll ortape-like product from which square or rectangular pieces can easily becut off Samples are preferably not fully dried; and hence, maintainprolonged pliability, elasticity, and tensile strength. The moisturecontent the tobacco composition ranges from about 12.5 to about 25percent.

The tape-like product can be formed into a roll, and positioned withinan outer container of the type described previously with reference toFIG. 6. That outer container then can be wrapped with an outer wrappingmaterial, using packaging conditions such as those of the type describedhereinbefore.

EXAMPLE 11

A tobacco composition having the general form of a tape or roll isprovided as follows.

A dry mix that is provided contains about 9 g rice starch(pregelatinized), about 20 g sodium alginate available as Manucol LD,about 5 g cinnamon powder and about 3 g menthol powder. Then, that drymix is combined with about 40 g of warm water (e.g., at about 30° C. toabout 45° C.) having about 16 g of glycerin dissolved therein in thepasta maker described in Example 3. During operation of the pasta maker,about 142 g of granulated tobacco material of the type described inExample 10 is introduced into the pasta maker along with the previouslydescribed aqueous mix.

The resulting blend is then extruded into flat pasta-like sheets ofdimension about 1.4 cm wide by about 30 cm long, by about 0.1 cm toabout 0.3 cm thick. Each sheet is further perforated at intervals ofabout 0.5 to about 1.5 cm intervals length-wise to obtain a roll ortape-like product from which square or rectangular pieces can easily becut off Samples are preferably not fully dried; and hence, maintainprolonged pliability, elasticity, and tensile strength. The moisturecontent the tobacco composition ranges from about 12.5 to about 25percent.

The tape-like product can be formed into a roll, and positioned withinan outer container of the type described previously with reference toFIG. 6. That outer container then can be wrapped with an outer wrappingmaterial, using packaging conditions such as those of the type describedhereinbefore.

EXAMPLE 12

A tobacco composition having the general form of a tape or roll isprovided as follows.

A dry mix that is provided contains about 20 g sodium alginate availableas Manucol LD and about 5 g mint flavor. Then, that dry mix is combinedwith about 50 g of warm water (e.g., at about 30° C. to about 45° C.)having about 16 g of glycerin dissolved therein in the pasta makerdescribed in Example 3. During operation of the pasta maker, about 195 gof granulated tobacco material of the type described in Example 10 isintroduced into the pasta maker along with the previously describedaqueous mix.

The resulting blend is then extruded into flat pasta-like sheets ofdimension about 1.4 cm wide by about 30 cm long, by about 0.1 cm toabout 0.3 cm thick. Each sheet is further perforated at intervals ofabout 0.5 to about 1.5 cm intervals length-wise to obtain a roll ortape-like product from which square or rectangular pieces can easily becut off Samples are preferably not fully dried; and hence, maintainprolonged pliability, elasticity, and tensile strength. The moisturecontent the tobacco composition ranges from about 12.5 to about 25percent.

The tape-like product can be formed into a roll, and positioned withinan outer container of the type described previously with reference toFIG. 6. That outer container then can be wrapped with an outer wrappingmaterial, using packaging conditions such as those of the type describedhereinbefore.

EXAMPLE 13

A combination of finely milled flue-cure and burley tobacco powder(e.g., about 25 g) is mixed with about 100 ml of a solution having about1 g potassium hydroxide in about 100 ml water. The resulting slurry isheated with constant stirring to about 60° C. to about 80° C. for about15 minutes. About 1 g of a sweetening agent available as SucraSweet HIS600 and about 15 g mannitol then are added, and the slurry is held atabout 60° C. to about 80° C. for another 15 minutes, while mixingconstantly to obtain a tobacco/water slurry. Meanwhile, a binder systemis prepared separately in a Warring blender. About 5 g sodium alginateavailable as Kelvis is first mixed at high shear with about 200 ml waterfor 5 minutes, followed by the slow addition of about 20 parts sodiumalginate available as Manucol LD, about 7 g rice starch(pregelantinized), about 2 g microcrystalline cellulose available asTicacel, about 10 g calcium carbonate and about 15 g glycerin,successively, while the blender is operated at medium to high shearspeed for approximately another 10 minutes. The binder and tobaccoslurry mixtures are then mixed together in the blender at medium to highshear speed for approximately another 5 minutes, with the addition ofthe about 2.5 g cinnamon and about 1.5 g menthol. After mixing, portionsof the final slurry are cast at about 0.1 cm to about 0.3 cm thicknessonto a stainless steel plate. The slurries are then dried to formtobacco sheets or films weighing about 95 g to about 125 g per squaremeter. The sheets are finally cut into smaller square or rectangularpieces, each weighing about 50 mg to about 150 mg. The resulting pieceshave the form of relatively slow dissolving strips. Those strips can beindividually packaged in outer packaging materials of the type describedpreviously with reference to FIG. 1.

EXAMPLE 14

A combination of finely milled flue-cure and burley tobacco powder(e.g., about 25 g) is mixed with about 100 ml of a solution having about2 g sodium carbonate in about 100 ml water. The resulting slurry isheated with constant stirring to about 60° C. to about 80° C. for about15 minutes. About 1 g of a sweetening agent available as SucraSweet HIS600 then is added, and the slurry is held at about 60° C. to about 80°C. for another 15 minutes, while mixing constantly to obtain atobacco/water slurry. Meanwhile, a binder system is prepared separatelyin a Warring blender. About 6 g sodium alginate available as Kelvis isfirst mixed at high shear with about 200 ml water for 5 minutes,followed by the slow addition of about 20 g rice starch(pregelantinized), about 10 g maltodextrin, about 15 g calcium carbonateand about 15 g glycerin, successively, while the blender is operated atmedium to high shear speed for approximately another 10 minutes. Thebinder and tobacco slurry mixtures are then mixed together in theblender at medium to high shear speed for approximately another 5minutes, with the addition of the about 4.9 g mint flavor. After mixing,portions of the final slurry are cast at about 0.1 cm to about 0.3 cmthickness onto a stainless steel plate. The slurries are then dried toform tobacco sheets or films weighing about 95 g to about 125 g persquare meter. The sheets are finally cut into smaller square orrectangular pieces, each weighing about 50 mg to about 150 mg. Theresulting pieces have the form of relatively slow dissolving strips.Those strips can be individually packaged in outer packaging materialsof the type described previously with reference to FIG. 1.

EXAMPLE 15

A combination of finely milled flue-cure and burley tobacco powder(e.g., about 15 g) is mixed with about 100 ml of a solution having about1.75 g sodium carbonate in about 100 ml water. The resulting slurry isheated with constant stirring to about 60° C. to about 80° C. for about15 minutes. About 0.5 g of a sweetening agent available as SucraSweetHIS 600 and about 7.5 g mannitol then are added, and the slurry is heldat about 60° C. to about 80° C. for another 15 minutes, while mixingconstantly to obtain a tobacco/water slurry. Meanwhile, a binder systemis prepared separately in a Warring blender. About 7.5 g konjac flouravailable as Nutritol GP 312 from FMC Bioplolymers Corporation is firstmixed at high shear with about 200 ml water for 5 minutes, followed bythe slow addition of about 15 g calcium carbonate, about 0.75 g sodiumchloride and about 7.5 g glycerin, successively, while the blender isoperated at medium to high shear speed for approximately another 10minutes. The binder and tobacco slurry mixtures are then mixed togetherin the blender at medium to high shear speed for approximately another 5minutes, with the addition of the about 1.25 cinnamon and about 0.75 gmenthol. After mixing, portions of the final slurry are cast at about0.1 cm to about 0.3 cm thickness onto a stainless steel plate. Theslurries are then dried to form tobacco sheets or films weighing about95 g to about 125 g per square meter. The sheets are finally cut intosmaller square or rectangular pieces, each weighing about 50 mg to about150 mg. The resulting pieces have the form of relatively slow dissolvingstrips. Those strips can be individually packaged in outer packagingmaterials of the type described previously with reference to FIG. 1.

EXAMPLE 16

A combination of finely milled flue-cure and burley tobacco powder(e.g., about 15 g) is mixed with about 100 ml of a solution having about1.75 g sodium carbonate in about 100 ml water. The resulting slurry isheated with constant stirring to about 60° C. to about 80° C. for about15 minutes. About 0.75 g of a sweetening agent available as SucraSweetHIS 600 then is added, and the slurry is held at about 60° C. to about80° C. for another 15 minutes, while mixing constantly to obtain atobacco/water slurry. Meanwhile, a binder system is prepared separatelyin a Warring blender. About 3.5 g sodium alginate available as Kelvis isfirst mixed at high shear with about 200 ml water for 5 minutes,followed by the slow addition of about 9.5 g rice starch(pregelatinized), about 5 g maltodextrin, about 5 g calcium carbonate,about 0.75 g sodium chloride and about 7.5 g glycerin, successively,while the blender is operated at medium to high shear speed forapproximately another 10 minutes. The binder and tobacco slurry mixturesare then mixed together in the blender at medium to high shear speed forapproximately another 5 minutes, with the addition of the about 1.25cinnamon and about 0.75 g menthol. After mixing, portions of the finalslurry are cast at about 0.1 cm to about 0.3 cm thickness onto astainless steel plate. The slurries are then dried to form tobaccosheets or films weighing about 95 g to about 125 g per square meter. Thesheets are finally cut into smaller square or rectangular pieces, eachweighing about 50 mg to about 150 mg. The resulting pieces have the formof relatively slow dissolving strips. Those strips can be individuallypackaged in outer packaging materials of the type described previouslywith reference to FIG. 1.

EXAMPLE 17

About 50 g of a granulated tobacco powder is mixed with about 100 ml ofwater in a Warring blender at low shear speed for about 5 minutes toobtain an aqueous tobacco slurry. Meanwhile a binder system is preparedin a separate blender by mixing about 5 g sodium alginate available asKelvis with about 200 ml water at high shear speed for about 5 minutes.About 15 g sodium alginate available as Manucol LD and about 5 ghydroxypropylcellulose available as Klucel EF are slowly added,successively, as the slurry is mixed for approximately another 5minutes. About 7.5 g glycerin is then added to the binder system and theslurry mixed for another 5 minutes. The aqueous tobacco slurry andbinder systems are then mixed together for another 5 minutes at mediumto high shear speed with the addition of about 2 g mint flavor. Thefinal slurry is subsequently cast, dried, and cut into thin film strips.Those relatively slow dissolving strips can be individually packaged inouter packaging materials of the type described previously withreference to FIG. 1.

EXAMPLE 18

About 50 g of a granulated tobacco powder is mixed with about 100 ml ofwater in a Warring blender at low shear speed for about 5 minutes toobtain an aqueous tobacco slurry. Meanwhile a binder system is preparedin a separate blender by mixing about 6 g sodium alginate available asKelvis with about 200 ml water at high shear speed for about 5 minutes.About 10 g sodium alginate available as Manucol LD is slowly added, asthe slurry is mixed for approximately another 5 minutes. About 14 gglycerin is then added to the binder system and the slurry mixed foranother 5 minutes. The aqueous tobacco slurry and binder systems arethen mixed together for another 5 minutes at medium to high shear speedwith the addition of about 5 g mint flavor. The final slurry issubsequently cast, dried, and cut into thin film strips. Thoserelatively slow dissolving strips can be individually packaged in outerpackaging materials of the type described previously with reference toFIG. 1.

1. A smokeless tobacco composition having a form that is not intended tobe smoked, that composition comprising at least two tobaccoformulations, wherein: (i) a first tobacco formulation is a processedmixture incorporating components that include tobacco and binding agent,said processed mixture being provided by contacting the components inwater; and (ii) the first tobacco formulation is formed so as to overlya second tobacco formulation.
 2. The smokeless tobacco composition ofclaim 1 wherein the first tobacco formulation is formed into one or moresheet-like shapes that are adapted to enwrap the second tobaccoformulation.
 3. The smokeless tobacco composition of claim 1 wherein thefirst tobacco formulation incorporates components that possess one typeof sensory characteristics, and the second tobacco formulationincorporates components that exhibit a different type of sensorycharacteristics.
 4. The smokeless tobacco composition of claim 2 whereinsaid second tobacco formulation is in the shape of a rod.
 5. Thesmokeless tobacco composition of claim 4 wherein the enwrapped said rodis cut into cylindrical pellets, and then both cut ends of each pelletare molded or sealed to form pillow-like pellets.
 6. The smokelesstobacco composition of claim 5 wherein said pillow-like pellets aredried at ambient temperature for about 12 hours.
 7. The smokelesstobacco composition of claim 5 wherein said pillow-like pellets aredried for about 20 minutes in a forced air oven at about 50° C. to about80° C.
 8. A smokeless tobacco formulation having a form that is notintended to be smoked, that tobacco formulation comprising a processedmixture incorporating tobacco and alginate binder, said processedmixture being provided by contacting the components in water to providea mixture, forming that mixture and removing moisture from that mixture.9. The smokeless tobacco formulation of claim 8 wherein the forming iscarried out using casting techniques.
 10. The smokeless tobaccoformulation of claim 8 wherein the forming is carried out usingextrusion techniques.
 11. The smokeless tobacco formulation of claim 8further incorporating glycerin.
 12. The smokeless tobacco formulation ofclaim 8 further incorporating a pH adjuster.
 13. The smokeless tobaccoformulation of claim 8 further incorporating at least onepolysaccharide.
 14. The smokeless tobacco formulation of claim 8 furtherincorporating a sweetening agent.
 15. The smokeless tobacco formulationof claim 8 further incorporating a filler.
 16. The smokeless tobaccoformulation of claim 8 further incorporating a starch-based material.